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<p>This study explores the development of cold-spray-deposited Fe-6.5 wt.%Si for soft magnetic material applications. We present experimental evidence for the successful deposition of Fe-6.5 wt.%Si powder via cold spray, emphasizing the role of carrier gas in optimizing deposition performance for high-temperature materials. Detailed scanning electron microscopy, energy dispersive spectroscopy, and electron back-scattered diffraction analysis reveal the impact of annealing on enhancing magnetic performance through grain growth and stored-strain relaxation. Additionally, the fabrication and analysis of a dual-layer gradient composition, consisting of Fe-3.5 wt.%Si and Fe-6.5 wt.%Si, is successfully demonstrated and characterized using scanning electron-based microscopy. These findings provide insights into leveraging cold spray technology as an additive manufacturing approach for developing magnetic laminates.</p>

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Unraveling the potential of Fe-6.5Si Cold Spray laminates

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月30日

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  • Hrishikesh Das,
  • Julian D. Escobar Atehortua,
  • Aditya Nittala,
  • Shivakant Shukla,
  • Tingkun Liu,
  • Tej Bahadur Poudel Chhetri,
  • Rajib Kalsar,
  • Christopher B. Smith,
  • Darrell R. Herling,
  • Keerti Kappagantula

摘要

This study explores the development of cold-spray-deposited Fe-6.5 wt.%Si for soft magnetic material applications. We present experimental evidence for the successful deposition of Fe-6.5 wt.%Si powder via cold spray, emphasizing the role of carrier gas in optimizing deposition performance for high-temperature materials. Detailed scanning electron microscopy, energy dispersive spectroscopy, and electron back-scattered diffraction analysis reveal the impact of annealing on enhancing magnetic performance through grain growth and stored-strain relaxation. Additionally, the fabrication and analysis of a dual-layer gradient composition, consisting of Fe-3.5 wt.%Si and Fe-6.5 wt.%Si, is successfully demonstrated and characterized using scanning electron-based microscopy. These findings provide insights into leveraging cold spray technology as an additive manufacturing approach for developing magnetic laminates.